Boiler Blog | Nationwide Boiler Inc.

When timing is everything, Nationwide Boiler's in-stock boiler program delivers the solutions today’s industry demands. In 2025, ourteam successfully delivered a fast-track project including a 180,000 lb/hr, 500 psig B&W package watertube boiler with CataStak™ SCR system to a major West Coast food processing plant, overcoming logistical and regulatory challenges to keep production on track.​

This delivery exemplifies our philosophy of “Boiler Procurement, Redefined” — giving customers immediate access to high‑capacity steam without the delays typical of traditional equipment sourcing.

Meeting Urgent Customer Needs with Strategic Boiler Procurement

The project began when a long-term customer faced a critical capacity challenge. As production needs outpaced their older equipment, the prospect of waiting a year for a new boiler was not viable. Thanks to our strategic in-stock boiler program, a high-capacity B&W package watertube boiler was available for immediate shipment, transforming a potential bottleneck into a rapid success story.​

Nationwide Boiler maintains a broad range of in-stock solutions such as this 180,000 lb/hr model, enabling rapid shipping and installation across the United States and globally. Inventory covers everything from compact 50 HP vertical units to large 255,000 lb/hr superheated watertube boilers, including essential ancillary equipment like feedwater systems, blowdown separators, water softeners, and CataStak™ SCR Systems for ultra-low NOx compliance. This diversity enables customers to access rapid replacements or planned upgrades without lengthy lead times and fabrication delays.​

This is exactly what “Boiler Procurement, Redefined” means: eliminating the long lead times and uncertainty typically associated with major steam equipment purchases.

Overcoming Logistics and Delivery Challenges

Transporting equipment of this scope requires both engineering expertise and logistical finesse. Because the 180,000 lb/hr boiler was too large to transport upright, it was rotated 90 degrees and shipped on its side from Kansas to California, with police escorts ensuring both public safety and on-time arrival. When trucking emerged as the optimal solution over rail due to control and delivery timeline concerns, the engineering and logistics teams coordinated every phase to maintain speed and reliability.​

Preparation also extended beyond transport. Early piping and foundation work enabled site teams to quickly tie in connections and reduce installation timeframes once the boiler arrived.​ By managing complex moves like this, we continue redefining what boiler procurement can look like — faster, smoother, and engineered for control.

Navigating Emissions Compliance and Customization

Permitting requirements are often the major hurdle for large steam projects, especially in states like California with strict air district requirements. In this case, the replacement boiler required compliance with stringent emissions standards including 2.5 PPM NOx, 10 PPM ammonia slip, and 25 PPM CO. Our project team worked closely with both the end-user and regulatory authorities, customizing the system with Nationwide’s CataStak™ SCR technology and an enhanced heat-recovery economizer to minimize emissions and maximize operating flexibility.​

The ability to match technical solutions such as fully metered controls and customized economizers to each customer’s needs establishes Nationwide Boiler as a trusted partner for food processors, petrochemical companies, and manufacturers with tight project windows and demanding performance expectations.​

Proactive Planning Pays Off for Mission-Critical Steam

A key takeaway for plants facing urgent steam shortages is that planning ahead is vital. Boiler owners and operators should consult with their team early to establish tie-in points, assess site needs, and prepare for seamless installation should an emergency arise. With standardized drawings, in-stock units, and engineered ancillary packages available, facilities can trust Nationwide Boiler to help them avoid costly downtime and accelerate timelines when every hour counts.​

This proactive approach aligns with our vision of “Boiler Procurement, Redefined” — enabling facilities to prepare for the unexpected and deploy solutions without delay.

The Nationwide Advantage: Inventory, Experience, and Customer Commitment

Whether the need is for new, reconditioned, or rental boilers, Nationwide Boiler’s extensive  inventory and experienced technical staff enable companies to address equipment failures or fast-track expansion plans. Our in-stock inventory spans a wide range of capacities, support equipment, and compliance solutions, ready to ship and ready to solve real-world challenges.​

Looking for a boiler solution ready on your schedule? Nationwide Boiler delivers on site and on time, backed by decades of expertise, redefining the traditional model for boiler procurement.

At Nationwide Boiler, we’ve spent more than four decades helping industries meet demanding emissions requirements with solutions that deliver reliability, performance, and proven results. Our CataStak™ Selective Catalytic Reduction (SCR) System is one of those solutions—engineered to achieve ultra-low, single-digit NOx emissions on package boilers and a wide range of fired equipment. As air-quality regulations continue to tighten, understanding NOx and the importance of emissions control is more critical than ever.

What Is NOx?

NOx, or nitrogen oxides, represents a group of highly reactive gases formed when nitrogen and oxygen combine during high-temperature combustion. These emissions are common in industrial boilers and fired equipment, including:

• Package boilers
• Fired heaters
• Gas turbines
• Heat recovery steam generators

The amount of NOx produced depends on several operational factors:

• Fuel type
• Burner design
• Peak combustion temperature
• System configuration
• Use of emissions-control technology such as an SCR

Why Reducing NOx Emissions Matters

Once released into the atmosphere, NOx contributes to a series of reactions that impact both environmental quality and human health. Even at low concentrations, these gases can significantly affect regional air quality.

• Ground-Level Ozone (Smog)
  NOx reacts with volatile organic compounds (VOCs) in the presence of sunlight to form ground-level ozone—a major component of smog. Unlike the protective ozone layer, this type of ozone is harmful, contributing to crop damage, reduced visibility, and stressed vegetation. 

• Acid Rain Formation
  When NOx combines with moisture in the atmosphere, it forms nitric acid, a leading cause of acid rain. Acid rain can accelerate the deterioration of buildings, deplete soil nutrients, and disrupt lakes and streams.

• Water Quality Concerns
  Nitrogen compounds from NOx emissions can wash into waterways, fueling algae growth. These algal blooms reduce oxygen levels, harm aquatic life, and create lasting ecological imbalances.

• Climate Influence
  While NOx itself is not a greenhouse gas, it contributes indirectly to climate change by forming ground-level ozone, which is considered a greenhouse gas. Reducing NOx helps minimize an operation’s overall environmental footprint.

• Human Health Considerations
  Exposure to NOx can irritate the respiratory system and worsen existing lung conditions. Elevated levels may increase asthma attacks, aggravate bronchitis, and reduce overall lung function. Children, older adults, and individuals with respiratory sensitivities face the greatest risk.

Nationwide Boiler’s Role in Emissions Compliance

Since the early days of federal emissions legislation, Nationwide Boiler has been a trusted partner in helping facilities meet—and exceed—air-quality requirements. Our team provides engineered solutions tailored to each application, supporting reliable performance and long-term compliance.

For operations that require deeper emissions reduction or consistent performance across a wide operating range, our CataStak™ SCR System delivers emissions compliance without compromise. The CataStak has been proven across hundreds of installations on boilers and fired equipment in demanding industrial environments. Its modular design supports both ammonia and urea-based reagent systems, allowing facilities to choose the solution that best aligns with their operational and safety requirements. With horizontal and vertical configurations, the CataStak can be engineered to fit a wide variety of system layouts, space constraints, and performance needs. Regardless of the application, the result is the same: reliable, near-zero NOx emissions and a system built for long-term, cost-effective operation.

Ultra-low NOx burners are another viable option, designed to minimize NOx formation at the source by optimizing air–fuel mixing and reducing peak combustion temperatures. These burners have consistently demonstrated the ability to achieve ultra low NOx emissions, as low as 5 ppm in many firetube boiler applications. Through ongoing research and development, we’ve also seen promising results at even lower levels in select operating conditions—particularly on smaller firetube boiler systems. While these advancements continue to be refined, they highlight the potential for future solutions that push emissions performance even further.

And lastly, for facilities looking to eliminate combustion-related emissions entirely, electric steam boilers offer a viable, zero-emissions-at-the-source alternative. Because they operate without fossil fuels, electric boilers do not produce NOx, CO, or greenhouse gases at the point of use. While they are not the right fit for every application—particularly where high steam capacities are required—they can be an effective option in regions with clean, reliable electricity or for processes with strict emissions or permitting requirements.

 Nationwide Boiler remains committed to helping facilities operate cleaner, more efficiently, and more sustainably. Our decades of experience—and the proven performance of our environmental solutions—ensure that your operation can meet today’s air-quality standards and future requirements with confidence.

Originally posted in July 2017, this blog has been updated to reflect current information and evolving air-quality regulations.

Celebrating Diversity, Connection, and Leadership in the Boiler Industry

Nationwide Boiler recently participated in the inaugural Women in the Boiler Industry (WIBI) Symposium, held in Minneapolis, MN, on October 15-17^th, 2025. Hosted by the American Boiler Manufacturer Association (ABMA), the event joined women and men within the boiler industry to celebrate diversity, foster connections, and advance the future of the boiler industry. Our company proudly sponsored the Welcome Networking Reception for this event, and we were thrilled to have Chelsey Ryker, Director of Marketing & Communications, represent our team.

Bringing together professionals from across North America, the WIBI Symposium was a two-day event full of inspiration and learning. Attendees participated in industry tours, keynote sessions, interactive workshops, and roundtable discussions focused on shaping a more inclusive and dynamic industry. The event included keynotes and fireside chats for building leadership presence and personal mastery, as well as roundtables and panels with trailblazers whose impact is igniting change throughout the boiler community.​ The event also included sessions on boiler code changes, financial management, boosting creativity and productivity through AI, positive communication, and boiler safety.

Nationwide Boiler’s Commitment to Visibility and Advancement

In addition to her participation, Chelsey also served on the WIBI Advisory Committee to help shape the impact of the event. She expressed  the importance of Nationwide Boiler’s support of events like this through a video interview in the weeks leading up to the WIBI Symposium. “Supporting WIBI means we’re investing in visibility, empowerment, and advancement of women in our field,” she noted, underscoring Nationwide Boiler’s dedication to fostering innovation through inclusion. “It’s about creating space for new voices, showing that Nationwide Boiler stands behind the people who are shaping our future.”​

She also shared her excitement about connecting with fellow women in the boiler industry and the value of building a community where stories, experiences, and diverse perspectives can be shared. “Women can be leaders in this industry; an industry that [is evolving to embrace greater diversity], and women bring a unique perspective,” she said. “Events like WIBI matter because they shift the narrative. They show that women not only belong in the industry but they’re already leading, innovating and driving change.” The WIBI initiative goes beyond networking; it's about opening doors to new opportunities and inspiring women to pursue leadership roles, fostering a more inclusive and forward-thinking industry.

Leadership, Recognition, and Looking Ahead

The WIBI Symposium concluded with a dynamic panel of distinguished leaders sharing philosophies and lessons learned, and new awards celebrated trailblazers and rising stars who are shaping the future of the sector. As one event organizer noted, “The 2025 WIBI Symposium was more than a meeting, it was the beginning of a movement.” This year’s event reinforced a powerful truth: progress happens when diverse voices lead the conversation and collaborate toward shared goals.

Nationwide Boiler is proud to champion this progress, continuing to lead initiatives that foster diversity, innovation, and an inclusive future for all professionals in the industry.

Let’s take a step back in time to a brisk day in October — a day that became a defining moment in Nationwide Boiler’s history. On October 17, 1989, at exactly 5:04 p.m. Pacific Daylight Time, a powerful 7.1 magnitude earthquake struck Northern California. For residents of the San Francisco Bay Area it was a moment frozen in time, one they would never forget.

It was a calm fall evening. More than 50,000 fans were settling into their seats at Candlestick Park for Game Three of the World Series, while millions more across the country tuned in to the live broadcast. As the stadium announcer provided pregame updates, no one could have anticipated what was about to unfold. Then, the ground began to shake. Screams erupted and the announcements stopped. ABC broadcaster Al Michaels, usually composed and articulate, was momentarily speechless. The energy of the stadium was replaced with an eerie silence. What followed was one of the most significant earthquakes in California’s history: a 7.1 magnitude event that would later be known simply as “the big one.”

In a matter of seconds, freeways collapsed, bridges broke apart, and buildings shifted from their foundations. The World Series was postponed. Fires erupted in multiple areas, including a major blaze in San Francisco’s Marina District, and millions of gallons of water were deployed by first responders to fight the flames. In the midst of widespread devastation, the city narrowly avoided a far worse outcome and utility services remained operational through the night, allowing emergency crews to respond effectively.

At Nationwide Boiler’s office in Fremont, Service Manager Neil McIntosh was still absorbing the shock of the quake. As he cleaned up broken glass and restacked books scattered across the office, he had an uneasy feeling that it would be a long night. And he was right — at 11pm that evening, the facility engineer from PG&E’s Potrero Power Plant, San Francisco’s primary power generation facility, called with a critical issue that could lead to the need for a rental boiler. And the standard question followed: “How fast can you respond?”

In the hours following the earthquake, PG&E engineers struggled to diagnose a serious problem: the plant’s electrically powered feedwater pumps, responsible for supplying water to the boilers that generated steam for turbine operation, had unexpectedly shut down. Under normal conditions, multiple backup systems would prevent any drop in water levels. But in this case, the boilers continued running without feedwater. When the pumps were eventually brought back online, it was already too late. The boilers were dangerously overheated, and it was no longer safe to reintroduce water. In a stopgap effort, a U.S. Navy ship docked next to the power plant was called in to provide emergency steam to cool the boilers. While helpful, this solution was temporary, and the city’s only other power plant was operating at full capacity to meet soaring demand. A failure at Potrero could have led to widespread outages. The only sustainable option was to deploy a high-capacity, fully equipped mobile steam plant that could deliver the right temperature, pressure, and controls to safely restart the system.

Within hours, a Nationwide Boiler 250 HP mobile boiler room was loaded and shipped to Potrero. With assistance from CalTrans and the California Highway Patrol, the unit navigated through a network of damaged freeways and arrived at the site. Shortly after arrival, the mobile boiler was brought online. The overheated boilers were cooled, the feedwater pumps were reactivated, and the turbines resumed power generation. Thanks to this rapid response, the city avoided losing a vital source of electricity at a time when it was needed most.

In the days that followed, the nation watched as rescue teams worked tirelessly to pull survivors from the rubble. The extent of the devastation was immense. But despite the tragedy, fires were brought under control, and emergency services maintained critical infrastructure under extraordinary pressure. Looking back, Neal McIntosh, a history enthusiast, often reflected on what could have happened. After the 1906 San Francisco earthquake, much of the city’s destruction was caused not by the quake itself, but by the fires that followed. Had Potrero’s boilers failed beyond recovery, the consequences in 1989 could have been similarly catastrophic.

Fortunately, Nationwide Boiler’s operations were largely unaffected, allowing our team to mobilize quickly and lend support when San Francisco needed it most. That day became more than a test of our equipment; it was a testament to the dedication of our people and the importance of being ready when every minute counts. What began as a moment of crisis became a defining chapter in Nationwide Boiler’s history — one that reminded us why readiness, reliability, and service are at the core of who we are.